1. CHEMICAL PROCESS DIAGRAM

2. Chemical Process Diagram
SCOPE:
Students will be able to know:-
Type of chemical process diagram
- Block Flow Diagram (BFD)
- Process Flow Diagram (PFD)
- Piping and Instrumentation Diagram (P&ID)
How to read and draw BFD, PFD and P&ID
Process equipments symbol and numbering

3. 3 Levels of Diagram Chemical Process Diagram -Block Flow Diagram (BFD)
-Process Flow Diagram (PFD)
-Piping and Instrumentation Diagram (P&ID)

4. BLOCK FLOW DIAGRAM (BFD)
The Block Flow Diagram (BFD)
BLOCK FLOW DIAGRAM (BFD)

5. The Block Flow Diagram (BFD)
BFD shows overall processing picture of a chemical
complex:
-Flow of raw materials and products may be included
on a BFD
-BFD is a superficial view of facility – ChE information is
missing

6. Figure 1.1: Block Flow Diagram for the Production of Benzene
The Block Flow Diagram (BFD)
Example 1:
Mixed Gas 2610 kg/hr
Toluene, C7H8 10,000 kg/hr
Reactor
Gas Separator
Benzene, C6H6 8,210 kg/hr
C6H6
CH4
C7H8
Hydrogen H2 820 kg/hr
Mixed Liquid
75% Conversion of Toluene
Reaction : C7H8 + H C6H6 + CH4
Figure 1.1: Block Flow Diagram for the Production of Benzene

7. Example 2 Production of Ethane from Ethanol
Ethanol is feed to continuous reactor with presence of Acid Sulphuric catalyzer to produce ethylene. Distillation process then will be applied to separate ethylene-H2O mixture. Ethylene as a top product is then condensate with condenser to perform liquid ethylene. Hydrogenation of ethylene applies in another reactor with presence of Nickel catalyzer to produce ethane as a final product. Develop BFD for these processes.
CH3CH2OH
H2SO4
CH2=CH2 + H2O
CH2=CH2 + H2 Ni
CH3CH3
Hot water out
Ethylene, CH2CH2 (g)
Ethylene liq. CH2CH2 (l)
Distillation column
Cold water in
Ethanol,
C2H5OH
H2SO4
Reactor 1
Reactor 2
Ethane, CH3CH3
CH2CH2
H2O Ni
Hydrogen, H2
H2O

8. The Block Flow Diagram (BFD)
Exercise 1:
Ammonia-air mixture is feed to the bottom stream of an absorber with flow rate of 10L/min. Water then feed to the upper stream of the same absorber with desired flow rate of 5L/min. There are two outputs from the absorber where upper stream is insoluble NH3 and bottom stream is NH3-Water mixture. This NH3-water mixture then feed up to a batch distillation column. The column produces ammonia gas as a top product which this product then will be condensate with a condenser to produce liquid ammonia. Develop Block Flow Diagram (BFD) for this process.

9. The Block Flow Diagram (BFD)
Answer 1
Hot water out
Insoluble ammonia
Ammonia liquid
Condenser
Water 5 L/min
Ammonia gas
Absorber
Batch
Distillation
Cold water in
Ammonia-water mixture
Ammonia-air mixture 10 L/min

10. The Block Flow Diagram (BFD)
Exercise 2:
Ethanol-water mixture is feed to a batch distillation column. This distillation process will produce ethanol vapour at the top product which then condensate to produce liquid ethanol which then collected into a distillate product tank. This liquid ethanol and an acetic acid liquid from a acid feed tank are then feed to a reactor. An exothermic chemical reaction will producing ethyl acetate (a type of ester). Draw BFD for this chemical process.

11. The Block Flow Diagram (BFD)
Answer 2
Hot water out
Condenser
Ethanol liq.
Reactor
Ethyl acetate
Batch
distillation
Distillate
product tank
Cold water in
Ethanol-water mixture
Acid feed
tank

12. The Process Flow Diagram (PFD)

13. The Process Flow Diagram (PFD)
SCOPE:
Students will be able to know:-
Process Unit symbology
How to read and draw PFD
Process equipments symbol and numbering

14. The Process Flow Diagram (PFD)
PFD shows all process engineering information:
-The topology of the process – showing the connectivity of
all the streams and the equipment.
-Use appropriate conventions – consistency is important in
communication of process information.

15. The Process Flow Diagram (PFD)
PFD will contains the following information:-
All major pieces of equipment (descriptive name, unique equipment no.), pumps and valves.
All the utility streams supplied to major equipments such as steam lines, compressed air lines, electricity, etc.
All process flow streams: identification by a number, process condition, chemical composition.
Basic control loops: showing the control strategy used to operate the process under normal operations.

16. The Process Flow Diagram (PFD)

17. The Process Flow Diagram (PFD)
PFD will contains the following information:-
- All major pieces of equipment (descriptive name, unique equipment no.), pumps and valves.
- All the utility streams supplied to major equipments such as steam lines, compressed air lines, electricity, etc.

18. The Process Flow Diagram (PFD)
Process Unit Symbology
Symbol
Description
Heat exchanger
H2O
Water cooler S
Steam heater
Cooling coil

19. The Process Flow Diagram (PFD)
Process Unit Symbology
Symbol
Description
Heater coil
Centrifugal pump
Turbine type compressor
Pressure gauge

20. The Process Flow Diagram (PFD)
Process Unit Symbology
Symbol
Name
Description
A separator unit used commonly to liquid mixture into gas phase
Stripper
Absorber
A separator unit used commonly to extract mixture gas into liquid phase

21. The Process Flow Diagram (PFD)
Process Unit Symbology
Symbol
Name
Description
A separator unit used commonly to crack liquid contains miscellaneous component fractions.
Distillation
column or
Liquid mixer
A process unit that used to mix several components of liquid.

22. The Process Flow Diagram (PFD)
Process Unit Symbology
Symbol
Name
Description
A process unit where chemical process reaction occurs
Reaction
chamber
Horizontal tank
or cylinder
A unit to store liquid or gas.

23. The Process Flow Diagram (PFD)
Process Unit Symbology
Symbol
Name
Description
A unit for heating.
Boiler
Centrifuge
A separator unit that to physically separated liquid mixture. (exp: oil-liquid)

24. The Process Flow Diagram (PFD)
Valve Symbology
Symbol
Name
Gate Valve
Globe Valve
Ball Valve
Check Valve
Butterfly Valve

25. The Process Flow Diagram (PFD)
Valve Symbology
Symbol
Name
Relief Valve
Needle Valve
3-Way Valve
Angle Valve
Butterfly Valve

26. Example 3 Production of Ethane from Ethanol
Ethanol is feed to continuous reactor with presence of Acid Sulphuric catalyzer to produce ethylene. Distillation process then will be applied to separate ethylene-H2O mixture. Ethylene as a top product is then condensate with condenser to perform liquid ethylene. Hydrogenation of ethylene applies in another reactor with presence of Nickel catalyzer to produce ethane as a final product. Develop PFD for these processes.
CH3CH2OH
H2SO4
CH2=CH2 + H2O
CH2=CH2 + H2 Ni
CH3CH3
T-100
Distillation Column
Ethanol
H2SO4
Ethylene
Ethylene liq.
Ethane Ni
Hydrogen
Cold water in
Hot water out
H2O
R-100
Reactor
E-100
Condenser
R-101
P-100
Pump
P-101
V-100
V-101
V-102
V-103
V-104
V-105
V-106
V-107
CV-101
CV-100

27. The Process Flow Diagram (PFD)
Exercise 3:
Ammonia-air mixture is feed to the bottom stream of an absorber with flow rate of 10L/min. Water then feed to the upper stream of the same absorber with desired flow rate of 5L/min. There are two outputs from the absorber where upper stream is insoluble NH3 and bottom stream is NH3-Water mixture. This NH3-water mixture then feed up to a batch distillation column. The column produces ammonia gas as a top product which this product then will be condensate with a condenser to produce liquid ammonia. Develop Process Flow Diagram (PFD) for this process.

28. The Process Flow Diagram (PFD)
Answer 3
T-100
Absorber Column
T-101
Batch Distillation Column
E-100
Condenser
Insoluble ammonia gas
Hot water out
Ammonia gas
Ammonia liquid
Water 5 L/min
Cold water in
Ammonia-air mixture 10 L/min
Ammonia-water mixture

29. The Process Flow Diagram (PFD)
The Process Flow Diagram (PFD)
Process Unit Tagging and Numbering
Process Equipment
General Format XX-YZZ A/B
XX are the identification letters for the equipment classification
C - Compressor or Turbine
E - Heat Exchanger
H - Fired Heater
P - Pump
R - Reactor
T - Tower
TK - Storage Tank
V - Vessel
Y - designates an area within the plant
ZZ - are the number designation for each item in an equipment class
A/B - identifies parallel units or backup units not shown on a PFD
Supplemental Information
Additional description of equipment given on top of PFD

30. The Process Flow Diagram (PFD)
Y Letter
Area No. 1
Area No. 2
Area No. 3

31. The Process Flow Diagram (PFD)
A/B Letter
Example
Ethylene
Ethylene liq.
Ethane Ni
Hydrogen
Cold water in
Hot water out
H2O
P-100 A/B
Hot water out
Ethylene
Ethylene liq.
Cold water in
Ethanol
H2SO4
Hydrogen
Ethane Ni
H2O
P-100 A
P-100 B
In PFD
In real plant, it means like above

32. The Process Flow Diagram (PFD)
PFD will contains the following information:-
All process flow streams: identification by a number, process condition, chemical composition.

33. The Process Flow Diagram (PFD)
Stream Numbering and Drawing
- Number streams from left to right as much as possible.
- Horizontal lines are dominant.
Yes No No

34. Example 4 Ethanol H2SO4 Ethylene Ethylene liq. Ethane Ni Hydrogen
Distillation Column
Ethanol
H2SO4
Ethylene
Ethylene liq.
Ethane Ni
Hydrogen
Cold water in
Hot water out
H2O
R-100
Reactor
E-100
Condenser
R-101
P-100
Pump
P-101 1 2 3 4 5 6 7 8 9 10
V-100
V-101
V-102
V-103
V-104
V-105
V-106
V-107
CV-100
CV-101

35. The Process Flow Diagram (PFD) (cont..)
Stream Information
Since diagrams are small not much stream information
can be included.
-Include important data – around reactors and towers, etc.
Flags are used
Full stream data,

36. The Process Flow Diagram (PFD) (cont..)
Stream Information - Flag
Temperature
600
300 3
Pressure 8 24 9 6 7
Mass Flowrate
10.3 1 10
Molar Flowrate
108
600 24 2 5 12
Gas Flowrate 11
Liquid Flowrate 4 13 24

37. Example 5 25 28 35 32.2 31.0 38 20 Ethanol H2SO4 Ethylene
Distillation Column
Ethanol
H2SO4
Ethylene
Ethylene liq.
Ethane Ni
Hydrogen
Cold water in
Hot water out
H2O
R-100
Reactor
E-100
Condenser
R-101
P-100
Pump
P-101 1 2 3 4 5 6 7 8 9 10
V-100
V-101
V-102
V-103
V-104
V-105
V-106
V-107
CV-100
CV-101

38. Stream Information - Full stream data,
Stream Number 1 2 3 4 5 6 7 8 9 10
Temperature (oC)
25.0
35.0
60.3 41 38
54.0
45.1
Pressure (psi) 28
32.2
31.0
30.2
31.3
24.0
39.0
2.6
Vapor fraction
Mass flow (tonne/hr)
10.3
13.3
0.82
20.5
6.41
0.36
9.2
20.9
11.6
Mole flow (kmol/hr)
108
114.2
301.0
1204.0
758.8
1204.4
42.6
1100.8
142.2
244.0

39. Example 6 25 28 35 32.2 31.0 38 20 Ethanol H2SO4 Ethylene
Distillation Column
Ethanol
H2SO4
Ethylene
Ethylene liq.
Ethane Ni
Hydrogen
Cold water in
Hot water out
H2O
R-100
Reactor
E-100
Condenser
R-101
P-100
Pump
P-101 1 2 3 4 5 6 7 8 9 10
V-101
V-102
V-103
CV-100
V-100
V-104
V-105
V-106
V-107
CV-101
Stream Number 1 2 3 4 5 6 7 8 9 10
Temperature (oC)
25.0
35.0
60.3 41 38 54
45.1
Pressure (psi) 28
32.2
31.0
30.2
31.3
24.0 39
2.6
Vapor fraction
Mass flow (tonne/hr)
10.3
13.3
0.82
20.5
6.41
0.36
9.2
20.9
11.6
Mole flow (kmol/hr)
108
114.2
301.0
1204.0
758.8
1204.4
42.6
1100.8
142.2
244.0

40. The Process Flow Diagram (PFD)
PFD will contains the following information:-
- Basic control loops: showing the control strategy used to operate the process under normal operations.

41. Example 7 25 28 35 32.2 31.0 38 20 Ethanol H2SO4 Ethylene
Distillation Column
R-100
Reactor
E-100
Condenser
R-101
P-100
Pump
P-101 25 28 35
32.2
31.0 38 20
Ethanol
H2SO4
Ethylene
Ethylene liq.
Ethane Ni
Hydrogen
Cold water in
Hot water out
H2O 1 2 3 4 5 6 7 8 9 10
LIC
V-100
V-101
V-103
V-102
CV-100
V-104
V-105
V-106
CV-101
V-107
Stream Number 1 2 3 4 5 6 7 8 9 10
Temperature (oC)
25.0
35.0
60.3 41 38 54
45.1
Pressure (psi) 28
32.2
31.0
30.2
31.3
24.0 39
2.6
Vapor fraction
Mass flow (tonne/hr)
10.3
13.3
0.82
20.5
6.41
0.36
9.2
20.9
11.6
Mole flow (kmol/hr)
108
114.2
301.0
1204.0
758.8
1204.4
42.6
1100.8
142.2
244.0

43. QUESTIONS?